Sheet metal is rarely used in its original form. For its further use, appropriate processing of the feedstock is necessary. The company "Rushar" offers bending and metal calculation services on modern equipment according to customer requirements. Such a technological operation makes it possible to form products of the required shape and size from flat rolled products. Unlike welding, sheet metal bending is less expensive and takes less time.

Applied equipment

Hydraulic press brakes are used to bend metal. Their parameters, dimensions, accuracy standards comply with the requirements of GOST 10560-88. This equipment provides adjustment of effort when bending sheet metal. The presses are equipped with a means of mechanizing the unloading of finished products.

On the equipment intended for multi-junction bending, a program control device is installed. The type of the latter is determined by the characteristics of a particular order and the type of rental.

All presses are equipped with devices for holding the finished product under load when the bending of the metal is completed. The design of the equipment allows it to be integrated into automatic lines for processing sheet metal.

In the process of bending sheet metal, the product receives a given shape. In this case, the outer layers are stretched, the inner ones are compressed, the middle ones retain their original structure. Mechanical and automatic bending of metal is carried out on the appropriate equipment. The essence of this technological process is to bend the thin sheet strip at a given angle. The minimum bend radii are calculated according to OST 1 00286-78.

Modern types of sheet metal bending

• Air (Air bending) . Such sheet bending is carried out by lowering the punch into the matrix to a predetermined depth. Their dimensions and angle are the same as in the finished part. The bending radius of the metal depends on the properties of the material and the opening of the matrix. The method is universal, it allows obtaining angles of various sizes.
• metal bendingby matrix (bottoming) . This technology is somewhat more accurate than the previous one. It is used for sheet metal up to 5 mm. However, matrix sheet bending does not allow bending the original workpiece at an angle of more than 90°.
• Machining using a pivot beam (Folding) . Used for bending thin sheet metal (up to 1 mm for structural steel). The method allows you to bend the workpiece in both directions, both up and down.
• Slip processing (wiping) . Similar to the previous method. Such sheet bending requires a separate tool for each thickness of rolled products.

Price list with sheet metal bending prices

thickness, mm	up to 100 mm.	up to 1250 mm.	up to 3000 mm.	up to 8000 mm.
0,5 - 0,8	RUB 5.00	RUB 12.00	RUB 25.00	RUB 70.00
1,0 - 1,2	RUB 6.00	RUB 14.00	RUB 25.00	-
1,5	RUB 6.50	RUB 15.00	RUB 26.00	-
2,0 - 2,5	RUB 7.00	RUB 16.00	RUB 26.00	-
3,0	RUB 7.50	RUB 17.00	RUB 33.00	-
4,0	RUB 9.00	RUB 23.00	-	-
5,0	RUB 10.00	RUB 25.00	-	-
6,0	RUB 12.00	RUB 28.00	-	-
8,0	RUB 14.00	-	-	-
10,0	RUB 15.00	-	-	-

Benefits of our services

The Rushar company provides services for bending sheet metal with a thickness of 0.5–6.0 mm. Our main advantages include:

• reasonable cost. Having our own production allows us to maintain affordable prices for sheet metal bending;
• high quality work. For sheet metal bending under the order, modern equipment is used. Hydraulic presses provide the necessary dimensional accuracy of the finished part;
• A complex approach. In addition to sheet metal bending services, we provide waterjet cutting, cold stamping and other custom processing.

High quality products combined with reasonable prices Convenient location The shortest order execution times All types of sheet metal work in one place

Such a technological process as sheet metal bending is a kind of technological operation of stamping. As a result of the impact of stamps on a flat sheet of metal, a curved part is obtained with all the necessary parameters specified in the drawing. That is, from ordinary flat metal, you can create a spatial figure of the desired parameters.

Varieties and application of the metal sheet bending process

There are several types sheet metal bending:

• single angle bending,


• double bending,


• multi-angle bending,


• sunset,


• perm


• Chasing,


• Flattening.

The use of such curved parts is quite wide, in every field of activity we find sheet products made of metals and alloys that have been subjected to some kind of processing and bending to give the desired shape. Sheet metal bending is applicable:

• For automotive components;


• For furniture;


• For doors;


• For parts intended for the railway industry;


• In aviation;


• In electronics;


• in shipbuilding;


• In construction.

Despite the fact that the process seems quite simple and fast, sheet metal bending technology is a complex and demanding job. To bend metal in the form of sheets, it is necessary to apply a powerful force, especially for products of great thickness.

Before starting the metal bending process, it is necessary to draw up a complete list of requirements for the final product. The most important factors include:

• Determination of the exact angle of the bend of the product;


• Determination of a constant bending angle over the entire length;


• As well as determining the flatness of the bent surface.

These three factors determine the ideal bending angle of the metal sheet.

For bending sheets of metal, specialized machines are used that adjust the original metal to all the specified parameters. Such machines can bend a sheet of metal and form an ideal product with the required configuration.

Such a technological process as welding is similar to bending metal sheets. However, the cost of welding and the duration of the operation in this case will be much greater. That is why sheet metal bending is the most suitable option for production efficiency.

Single-angle, or free, bending of metal sheets

In terms of sheet bending, single-angle bending is the simplest bending process in which the inner surfaces of the sheet metal are compressed by an external force, and the outer surfaces are stretched. Thus, the sheet of metal is bent at one angle. This method is also called free flexible metal.

Feature Free sheet metal bending lies in the fact that the equipment that allows this process to be carried out consists of a so-called matrix acting directly on the sheet of metal, and walls on which this sheet rests under the pressure of the matrix. There is an air gap between the walls and the sheet.

If there is no air gap, and the walls fit snugly against the sheet of metal, then this method is called calibration.

Benefits of Free Bending

The advantages of this method include:

• The ability to obtain any angle of metal bending: from the index of the opening angle of the matrix to 180 degrees.


• Cost savings for the tool.


• Free bending requires less force than sizing.


• For free bending, you need the simplest press with minimal effort.

The disadvantages of this kind of sheet metal deformation include:

• Inaccuracy of bending angles when using thin metal;


• The accuracy of copying corners is reduced when using metal of different quality.


• This method cannot be used for specific bending processes.

More details can be found in the equipment designed for sheet metal bending, taking part in the international exhibition, which is organized by the Central Exhibition Complex "Expocentre". This forum will present various devices, tools and equipment for metalworking, including machines and presses for bending metal sheets.

Thanks to such forums and exhibitions of equipment, the metallurgy and metal processing industry is developing, new technologies and devices are appearing at factories, which affects the quality of products and the duration of their manufacture.

Many people ask the question: how to bend a sheet of metal evenly? And it is not surprising, because when performing construction work, it may be necessary to perform a similar procedure.

Pipes of small diameter are bent with a vice. Very often during construction processes there is a need to bend pipes of a rather large diameter. For such work, special machines are needed, on which metal sheets and pipes are bent. The bent component is not deformed.

How to bend a sheet of metal evenly? Stages:

	General technology, principles and features of metal sheet bending.
	What metal can be bent? Brass, copper and aluminum are best suited for processing and shaping.
	Bending tools. Before starting work, you should prepare a diagram of the future product and calculate the required angle. After that, you need to acquire tools and materials.
	Self-manufactured machine for bending sheet metal. Materials and action plan.

Tip: when bending parts, its thickness, plasticity are taken into account and the radius of curvature is determined.

Metal bending technology

Bending sheet metal involves the implementation of certain actions that lead to the fact that the material takes on the desired shape. The metal bending process is performed without the help of welding or other connections that reduce the durability and strength of the material.

When bent, the outer layers of the product are stretched, and the inner ones are compressed. The technology is to bend one part in relation to the other at the required angle.

During bending, the metal sheet undergoes deformation. Its value depends on the thickness of the product, plasticity, bending angle and bending speed. The process itself is carried out on equipment, due to which damage is not formed. If the part is bent incorrectly, then various defects can occur on its surface, as a result of which the metal receives various damages on the bending line, which can lead to its breakage.

The bending stress must be greater than its stiffness limit. As a result of bending, plastic deformation can occur. In this case, after the bending operation, the finished structure will retain the shape that was given to it.

Benefits of the flat bending process for sheet metal:

1. High process performance.
2. As a result of bending, a workpiece without a seam can be obtained.
3. The finished structure is highly resistant to corrosion.
4. Rust does not form at the fold.
5. The structure is solid.
6. High strength.

Flaws:

1. Special equipment is quite expensive.
2. Manual bending is quite laborious.

Unlike structures made by bending metal, welded structures have a weld that is subject to rust and corrosion.

Bending of products is carried out manually or using special devices. Manual bending is a complex and time-consuming procedure that is performed using pliers and a hammer. If you need to evenly bend a sheet of metal of small thickness, use a mallet.

Bending of sheet metal is carried out using rollers, roller machines or a press. To give the material the shape of a cylinder, hydraulic, manual or electrically conductive rollers are used. Pipes are produced in a similar way.

Sheet metal bending is used for domestic construction purposes for the production of gutters, metal frames, profiles, pipes and other structures. When bending the material with your own hands, you can make pipes of different diameters. With the help of machines, products with a zinc coating are bent. To do this, make a machine, preferably according to a template.

When bending any product, its parameters should be determined. The length of the structure is calculated taking into account the radius. For workpieces that are bent at a right angle, without the formation of rounding, the allowance should be 0.6 mm from the total thickness of the sheet.

You can bend the following metals yourself:

• copper;

• brass;

• aluminum.

The bending radius will depend on the quality of the metal and the bending option.

How to evenly bend a sheet of metal with your own hands?

For the manufacture of staples by bending, the following tools and materials are used:

• vise;
• a metal sheet;
• frame;
• hammer;
• electric saw for metal;
• bar.

In advance, according to the scheme, the length of the workpiece strip is calculated and the bending of the metal sheet is calculated. Based on each bend, a margin of 0.5 mm in thickness is made and 1 mm per bend of the ends to the side. According to a pre-drawn scheme, the workpiece is cut out and a mark is made of the place of the bend. In order to bend the material, a vise with squares is used.

First, at the level of bending, you need to clamp the workpiece in a vice. Then, using a hammer, the first bend is made. The workpiece is rearranged in a vice and clamped with a frame together with a bar, after which a second bend is performed.

The workpiece is removed and a mark is made on the length of the legs of the bracket. She, together with the bar, is bent with a frame and both her legs are bent at the same time. The triangle specifies the bend. If it is not done correctly, the bend should be corrected with a frame bar and a hammer. When the bending procedure is completed, the structure is filed to the desired parameters.

How to evenly bend a sheet of metal: making a machine with your own hands

In order to create a device that allows you to bend a metal sheet at home, you need to prepare the following materials and tools:

• corner 80 mm;
• bolts;
• metal beam I-beam 80 mm;
• loops;
• welding machine;
• clamps;
• handles;
• table.

All work begins with the preparation of the base of a home-made machine from a profile - an I-beam 80 mm. After that, an 80 mm corner is screwed on top of the I-beam with two bolts. During bending, it will fasten the workpiece. Three hinges from steel doors are welded under the corner, the second halves of which are welded to the corner itself.

To perform bending, two 800 mm handles are welded to the corner, with which it will be possible to turn the machine. The sheet bender is pressed against the table with the help of two clamps. The clamping bracket is unscrewed. Then the workpiece is laid, and the corner is moved into place.

If necessary, it can be lifted without removing it. After that, the material is threaded between the I-beam and the corner. The metal sheet is neatly aligned. The bolts are tightened and by turning the workpiece is bent to the required angle.

A homemade machine is not a universal device, as it is used to bend sheets of small thickness. If there is a need to bend material with a large thickness, machines made in production should be used.

Such a technological operation as sheet metal bending allows, with minimal physical effort, to form a workpiece of the required configuration.

An alternative to bending rolled metal is the welding process, but in this case it takes much more time, and in financial terms it costs a little more.

Sheet metal bending can be done manually or automatically, however, in both cases, the technology of the process itself remains unchanged.

In the case when rolling is carried out, which has a large radius, as a rule, the neutral layer is located in the middle part of the thickness.

In turn, if the minimum radius is taken, then the aforementioned layer is already displaced directly towards the area of ​​material compression.

In industrial production, sheet metal bending technology is carried out using special equipment, while a preliminary calculation is made and the corresponding GOST is taken into account.

Do-it-yourself technology for bending rolled products has its own characteristics, moreover, the necessary calculation must also be made and GOST taken into account.

In this case, a special device is used, and in order to change the configuration of the metal sheet, it is necessary to make certain efforts and be sure to take into account the calculation.

Several different techniques can be used to change the shape of rolled metal.

Very often in this case, welding is used, however, such a thermal effect on the metal not only greatly affects its structure, but also significantly reduces its strength indicators, and, accordingly, reduces the service life.

In this case, it is possible to change the shape of the sheet metal due to a certain force, at which structural changes do not occur in the workpiece.

The peculiarities of bending rolled metal are that when performing this locksmith operation, the outer layers of the material are stretched and, accordingly, the inner layers are compressed.

The technology of bending any sheet metal lies in the fact that part of the rolled product is bent relative to the other at a strictly defined angle.

The calculation allows you to get the value of the given inflection angle.

Of course, due to the applied force, the metal itself undergoes deformation in a certain way, which has an acceptable limit, which, according to GOST, depends on such parameters as the thickness of the material, the magnitude of the bending angle, as well as the fragility and speed of the operation.

This technological operation is carried out on special equipment, which makes it possible to end up with a product without any defects.

In conditions where the work is done by hand, a special device is used to bend the metal.

In both cases, it must be taken into account that if the product is bent with violations, then microcracks will form on the surface of the material, which will subsequently cause the metal to weaken directly at the bend, which can lead to serious consequences.

Modern capabilities make it possible to bend rolled products of various thicknesses, while the generated stress must exceed such a parameter as the elastic limit.

In any case, the deformation of the sheet metal must be plastic.

It should be noted that the seamless structure obtained in this way will have high strength and have a certain resistance to corrosion.

Types and types of bending

Any bending of metal can be done both by hand and using special professional equipment designed for this purpose.

It should be noted that when performing this technological operation with your own hands, you will have to spend certain physical efforts and time.

In this case, bending is carried out with the help of pliers and a hammer, in some individual cases a special device is used.

It should be noted that do-it-yourself bending of a thin metal sheet, as well as aluminum, is carried out using a mallet.

At industrial enterprises, they try to automate this process in every possible way and use rollers of manual or hydraulic types directly for bending, as well as special roller units.

For example, to give the product a cylindrical shape, metal bending is carried out using rollers. Thus, pipes, chimneys, gutters and much more are obtained.

Most often, in industrial enterprises, metal bending is carried out on special bending presses.

Depending on the functionality, such presses can have a different design and, accordingly, sizes.

It should be noted that modern equipment allows performing high-tech operations with metal.

So, new industrial machines make it possible to simultaneously bend a sheet along several lines in one working cycle, which makes it possible to produce parts of any complexity.

As a rule, such equipment is quite easy to operate.

You can quickly reconfigure it to work with other material.

This operation requires special attention if it is necessary to bend aluminum sheet.

This is due, first of all, to the fact that sheet aluminum has slightly different strength and elasticity parameters from other types of metals.

self bending

Each metal has its own GOST, which must be taken into account when calculating the minimum bending radius of the sheet.

The calculation in which the parameters are indicated is always individual. Features of bending a metal sheet take into account not only the minimum bending radius, but also the coefficient of elasticity, as well as strength characteristics.

Bending a metal sheet allows you to get a profile with a different configuration, prefabricated partitions, slopes, as well as many other products.

Before moving on to metal bending, it is necessary to make an appropriate calculation in accordance with GOST and determine the minimum radius of the bend line.

The length of the bent strip is also necessarily determined, while it is necessary to make a minimum allowance directly for each bending line.

The sheet metal itself made of aluminum, stainless steel, etc. should, if necessary, be aligned and cut in accordance with the drawing. Do-it-yourself cutting is usually carried out with scissors using the appropriate technology. If you don't put in the effort, nothing will work.

The metal blank is firmly clamped in a vise of suitable dimensions along the drawn bend line, after which the first bend is made using a heavy hammer.

After that, the paws of the bracket are marked and, in a vice, with the help of a hammer, both paws are bent in a given direction.

At the end of the work, using a square, you need to make sure that the workpiece meets all the specified parameters.

If there are some discrepancies with the preliminary calculations, then they should be corrected in the same sequence.

In more detail about how metal sheets are bent with your own hands using a vice and a hammer, see the video below.

Metal cutting procedure

As a rule, before bending metal blanks, they are given the shape specified by the drawing, which makes it possible to simplify the work and obtain a more accurate bend radius.

Cutting a metal sheet is a separate technical operation, which is carried out according to its own technology.

In most cases, metal blanks are cut using sheet shears, which are called guillotines.

Such machines, as a rule, are installed at enterprises and allow you to quickly complete the necessary work, while taking into account the bending radius and material density.

At home, metal cutting is carried out using special locksmith scissors.

It should be noted that manual scissors are used to cut metal with a minimum thickness.

For thicker metal, chair or roof shears should be used.

Cutting metal at home, if necessary, can be done with a hacksaw.

In this case, you will have to spend some physical effort and monitor the quality of the resulting cut.

If metal is cut with a hacksaw, then during the work, the tension of the blade should be controlled, since the evenness of the cut largely depends on this.

How to cut a metal sheet with your own hands is described in the video below.

Sheet metal bending is one of the most common cold and hot deformation operations. It is characterized by low energy consumption, and with the correct development of the technical process, it makes it possible to successfully produce three-dimensional products of various shapes and sizes from flat blanks.

In accordance with the tasks set, sheet metal bending technology is being developed for the following options:

1. Single-angle (sometimes called V-shaped flexible).
2. Two-angle or U-shaped bending.
3. Multi-angle bending.
4. Radius bending of sheet metal (sealing) - obtaining products such as loops, galvanized clamps, etc.

The bending forces are small, so it is mainly performed in a cold state. An exception is the bending of a steel sheet made of low-plasticity metals. These include duralumin, high-carbon steels (containing an additional significant percentage of manganese and silicon), as well as titanium and its alloys. They, as well as blanks made of thick sheet metal with a thickness of more than 12 ... 16 mm, are mainly hot-bent.

Bending is combined with other sheet metal stamping operations: cutting and bending, with punching or punching are often combined. Therefore, for the manufacture of complex multidimensional parts, dies designed for several transitions are widely used.

A special case of sheet metal bending is tension bending, which is used to obtain long and narrow parts with large bending radii.

Depending on the size and type of the workpiece, as well as the required characteristics of the product after deformation, the following are used as:

• Vertical with mechanical or hydraulic drive;
• Horizontal hydraulic presses with two sliders;
• Forging bulldozers - horizontal bending machines;
• Pipe and profile bending machines;
• Universal bending machines.

To obtain structures that are unique in shape and size, in particular, turbine boilers, etc., exotic technologies for bending sheet steel are also used, for example, by explosion energy. In contrast, the question - how to bend tin - does not cause difficulties, since the plasticity of this material is very high.

A characteristic feature of sheet bending machines is reduced deformation rates, increased dimensions of the die space, and relatively low energy consumption. The latter is the basis for a wide production of galvanized material intended for deformation. They are particularly popular in small workshops as well as individual users.

Despite the apparent simplicity of the technology, it is difficult to determine the balance of stresses and deformations of the state in the workpiece. In the process of bending the material, stresses arise in it, initially elastic, and then plastic. At the same time, the bending of the sheet material is characterized by a significant deformation unevenness: it is more intense at the bending corners, and is almost invisible at the ends of the sheet blank. Sheet metal bending is characterized by the fact that its inner layers are compressed, and the outer ones are stretched. The conditional line that separates these zones is called the neutral layer, and its precise definition is one of the conditions for defect-free bending.

In the process of bending, rolled metal receives the following shape distortions:

• Change in thickness, especially for thick plates;
• Springing / springing - spontaneous change in the final bending angle;
• Folding of a metal sheet;
• The appearance of metal flow lines.

All these circumstances must be taken into account when developing the stamping process.

Stages and sequence of technology

Here, and in the future, we will focus on the processes of stamping sheet metal in a cold state.

Development is carried out in the following sequence:

1. The design of the part is analyzed.
2. The force and work of the process is calculated.
3. The standard size of the production equipment is selected.
4. A drawing of the original workpiece is being developed.
5. Deformation transitions are calculated.
6. Technological equipment is being designed.

An analysis of the suitability of the capabilities of the source material is necessary in order to find out its suitability for stamping according to the dimensions shown on the drawing of the finished part. The stage is performed on the following positions:

• Checking the plasticity of the metal and comparing the result with the level of stress that occurs during bending. For low-ductility metals and alloys, the process has to be divided into several transitions, and interoperational annealing should be planned between them, which increases plasticity;
• Possibility of obtaining a bending radius at which no cracking of the material will occur;
• Determination of probable distortions of the profile or thickness of the workpiece after pressure treatment, especially with complex contours of the part;

Based on the results of the analysis, sometimes a decision is made to replace the original material with a more ductile one, about the need for preliminary softening heat treatment, or to preheat the workpiece before deformation.

A mandatory point in the development of the technological process is the calculation of the minimum allowable bending angle, bending radius and springback angle.

The bending radius r min is calculated taking into account the plasticity of the metal of the workpiece, the ratio of its dimensions and the speed at which the deformation will be carried out (hydraulic presses, with their reduced slider speeds, are preferable to faster mechanical presses). With a decrease in the value of r min, all metals undergo the so-called thinning - a decrease in the initial thickness of the workpiece. The intensity of thinning determines the thinning factor λ, %, which shows how much the thickness of the final product will decrease. If this value turns out to be more critical, then the initial thickness s of the workpiece metal has to be increased.

For low-carbon sheet steels, the correspondence between the above parameters is given in the table (see Table 1).

Thus, under certain conditions, the metal of the workpiece can even bulge somewhat.

No less important is the determination of the minimum bending radius, which also depends on the initial thickness of the metal, the location of the rolled fibers and the ductility of the material (see Table 2). In the event that the bend radius is too small, the outer steel fibers can break, which violates the integrity of the finished product. Therefore, the minimum radii are usually counted according to the largest deformations of the extreme parts of the workpiece, taking into account the relative narrowing ψ of the deformable material (set according to the tables). In this case, the amount of deformation of the workpiece is also taken into account. For example, for small deformations, the dependence is used

and for large deformations, a more accurate equation of the form

The effect of possible springback can be taken into account using the data on the actual springback angles β, which are given in table 3. The data in the table correspond to the conditions of one-angle bending.

Determining the bending force

The power parameters of bending depend on the plasticity of the metal and the intensity of its hardening during deformation. In this case, the direction of rolling of the original billet is important. The fact is that after rolling, the metal acquires the property of anisotropy, when the residual stresses in the direction of the rolling axis are less than in the opposite direction. Accordingly, if along the fibers, then at the same degree of deformation, the probability of destruction of the workpiece is significantly reduced. Therefore, the bending edge is positioned in such a way that the angle between the direction of rolling and the location of the blanks in the sheet, strip or strip is minimal.

To calculate the force parameters, it is specified how the deformation will be performed. It is possible by a bending moment, when the workpiece is placed on the clamps / stops, and then freely deformed, or by force, when at the final moment of the process the semi-finished product rests on the working surface of the matrix. Free bending is simpler and less energy intensive, but bending with calibration makes it possible to obtain more accurate parts.